[scosman]

Problem

Production alerts in Nathan-admin kept repeating every hour:

pr_management.sweep failed: D1_ERROR: too many SQL variables at offset 357: SQLITE_ERROR {"repo":"Kiln-AI/Kiln","number":1959}
pr_management.refresh failed: D1_ERROR: too many SQL variables at offset 357: SQLITE_ERROR {"attempts":3}

At the end of every refresh, store.deleteEvents deletes the PR's processed webhook events. It binds repo, number and one id IN (?, …) value per event. Cloudflare D1 allows 100 bound parameters per query, so a PR with 99 or more pending events fails. Offset 357 is exactly where the 101st parameter sits in that query.

Kiln-AI/Kiln#1959 hit this because every check_run and status event is stored. A push to a large CI matrix records hundreds of them within one debounce window. When the delete failed, the events were never removed, so every later sweep and refresh of that PR failed the same way until the 7-day prune.

Fix

• src/core/db.ts: adds MAX_BOUND_PARAMS = 100 and inListChunks(values, otherParams), a shared helper. It splits an IN list into chunks that fit alongside the statement's other parameters.
• deleteEvents: deletes in chunks, all in one db.batch, so a PR's events are still consumed together or not at all.
• openRecords(repos): had the same unbounded repo IN (…). It's used by the sweep, the daily report and the personal queue. It now queries in chunks and merges the rows in the same repo, number order. This one couldn't fail yet because the tracked repo list is short.
• Rest of the codebase: no other query builds a variable-length list.

Tests

• New regression tests for refresh, the sweep and the store use 250 events or repos. All four failed before the fix with the exact production error.
• A test in test/core/db.test.ts checks that local D1 accepts 100 parameters and rejects 101, like production. If that ever changed, the regression tests would stop testing anything.
• npm run check passes: lint, typecheck, config, imports, and 810 tests.

After deploy

The first hourly sweep should clear #1959's backlog of events. Nothing needs to be done by hand.

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